Đây là Cẩm nang sửa chữa dành cho hộp số C50 của Toyota. Hộp số này lắp trên xe Toyota Vios và Toyota Yaris. Là loại hộp số cơ khí. Loại hộp số ngang. Hiện nay, 2 dòng xe Vios và Yaris lắp hộp số này vẫn đang sử dụng rất nhiều ngoài thị trường.
Trang 1MX
Trang 2MX
Trang 3MX
Trang 4DISASSEMBLY
1 REMOVE MANUAL TRANSMISSION FILLER PLUG
(a) Remove the manual transmission filler plug and gasket from the manual transmission case
2 REMOVE DRAIN PLUG SUB-ASSEMBLY
(a) Remove the drain plug sub-assembly and gasket from the manual transmission case
3 REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY
(a) Remove the bolt and speedometer driven hole cover sub-assembly from the transaxle case
(b) Remove the O-ring from the speedometer driven hole cover sub-assembly
4 REMOVE SPEEDOMETER SENSOR (w/o ABS)
(a) Remove the bolt and speedometer sensor from the transaxle case
5 REMOVE BACK-UP LIGHT SWITCH ASSEMBLY
(a) Separate the back-up light switch wire harness from the 2 clamps
(b) Using SST, remove the back-up light switch assembly and gasket from the manual transmission case
SST 09817-16011
6 REMOVE SELECTING BELL CRANK ASSEMBLY
(a) Remove the 2 bolts and nut and remove the selecting bell crank assembly from the manual transmission case
(b) Remove the control shift lever bush
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Trang 57 REMOVE FLOOR SHIFT CONTROL SHIFT LEVER
(a) Remove the nut and spring washer
(b) Using a brass bar and a hammer, remove the lock pin
(c) Remove the floor shift control shift lever
8 REMOVE SHIFT LEVER DAMPER
(a) Remove the nut and spring washer
(b) Using a brass bar and a hammer, remove the lock pin
(c) Remove the shift lever damper
9 FIX MANUAL TRANSAXLE ASSEMBLY
(a) Place the manual transaxle assembly on wooden blocks
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Trang 610 REMOVE LOCK BALL ASSEMBLY NO.1
(a) Remove lock ball assembly No 1 from the manual transmission case
11 REMOVE SHIFT GATE PIN
(a) Remove the shift gate pin and washer from the transmission case
12 REMOVE CONTROL SHAFT COVER
(a) Remove the 4 bolts, control shaft cover and gasket from the manual transmission case
13 REMOVE CONTROL SHAFT COVER OIL SEAL
(a) Using a screwdriver, remove the control shaft cover oil seal from the control shaft cover
14 REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY
(a) Remove the shift and select lever shaft assembly from the transmission case
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Trang 715 REMOVE MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY
(a) Remove the 9 bolts
(b) Using a plastic hammer, carefully tap the projection
of the manual transmission case cover assembly to remove the manual transmission case cover from the manual transmission case
sub-NOTICE:
Do not damage the manual transmission case.
16 REMOVE MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT
(a) Using a chisel and a hammer, loosen the staked part of the manual transmission output shaft rear set nut
(b) Engage the 2 gears simultaneously to lock the transmission
(c) Remove the manual transmission output shaft rear set nut
(d) Disengage the 2 gears
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Trang 817 REMOVE GEAR SHIFT FORK NO.3
(a) Remove the gear shift fork lock bolt from gear shift fork No 3
(b) Remove transmission hub sleeve No 3 with gear shift fork No 3 from transmission clutch hub No 3
18 INSPECT 5TH GEAR THRUST CLEARANCE
(a) Using a dial indicator, measure the 5th gear thrust clearance
Standard clearance:
0.10 to 0.55 mm (0.0039 to 0.0217 in.) Maximum clearance:
0.55 mm (0.0217 in.)
If the clearance exceeds the maximum, replace transmission clutch hub No 3, the 5th gear or input shaft rear radial ball bearing
19 INSPECT 5TH GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 5th gear radial clearance
Standard clearance:
KOYO made:
0.015 to 0.058 mm (0.0006 to 0.0023 in.) NSK made:
0.015 to 0.056 mm (0.0006 to 0.0022 in.) Maximum clearance:
KOYO made:
0.058 mm (0.0023 in.) NSK made:
0.056 mm (0.0022 in.)
If the clearance exceeds the maximum, replace the 5th gear, 5th gear needle roller bearing or input shaft
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Trang 920 REMOVE TRANSMISSION CLUTCH HUB NO.3
(a) Using 2 screwdrivers and a hammer, tap out the snap ring
SST 09950-40011 (09951-04020, 09952-04010,
09953-04030, 09954-04010, 09955-04011), 09950-60010 (09951-00180)
(c) Remove the 3 synchromesh shifting keys and 2 synchromesh shifting key springs from transmission clutch hub No 3
21 REMOVE 5TH GEAR NEEDLE ROLLER BEARING
(a) Remove the 5th gear needle roller bearing and 5th gear bearing spacer from the input shaft
22 REMOVE 5TH DRIVEN GEAR
(a) Using SST, remove the 5th driven gear from the output shaft
SST 09950-30012 (09951-03010, 09953-03010,
09954-03010, 09955-03021), 09950-60010 (09951-00180)
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Trang 1023 REMOVE BEARING RETAINER REAR
(a) Remove the 5 bolts and bearing retainer rear from the manual transmission case
24 REMOVE OUTPUT SHAFT REAR BEARING HOLE SNAP RING
(a) Using a snap ring expander, remove the output shaft rear bearing hole snap ring from the output shaft
25 REMOVE INPUT SHAFT REAR BEARING HOLE SNAP RING
(a) Using a snap ring expander, remove the input shaft rear bearing hole snap ring from the input shaft
26 REMOVE REVERSE IDLER GEAR SHAFT BOLT
(a) Remove the reverse idler gear shaft bolt and reverse idler gear shaft gasket from the manual transmission case
27 REMOVE SHIFT FORK SHAFT SHAFT SNAP RING
(a) Using 2 screwdrivers and a hammer, tap out the snap ring from gear shift fork shaft No 2
Trang 1128 REMOVE SHIFT DETENT BALL
(a) Using a hexagon wrench, remove the 2 shift detent ball plugs from the manual transmission case
(b) Using a magnetic finger, remove the 2 shift detent ball spring seats No 1, 2 shift detent ball springs and 2 shift detent balls from the manual
29 REMOVE LOCK BALL ASSEMBLY NO.2
(a) Using a hexagon wrench, remove lock ball assembly No 2 from the manual transmission case
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Trang 1230 REMOVE MANUAL TRANSMISSION CASE
(a) Remove the 3 bolts from the front transaxle case
(b) Remove the 13 bolts from the manual transmission case
(c) Using a brass bar and a hammer, carefully tap the projections of the manual transmission case to remove the transmission case from the transaxle case
NOTICE:
Do not damage the manual transmission case and transaxle case.
31 REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY
(a) Remove the reverse idler gear sub-assembly, thrust washer and reverse idler gear shaft from the front transaxle case
32 REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY
(a) Remove the 2 bolts and reverse shift arm bracket assembly from the front transaxle case
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Trang 1333 REMOVE GEAR SHIFT FORK SHAFT NO.2
(a) Remove the 2 bolts from gear shift fork No 2 and gear shift head No 1
(b) Remove gear shift fork shaft No 2 and gear shift head No 1 from the front transaxle case
34 REMOVE GEAR SHIFT FORK SHAFT NO.1
(a) Using 2 screwdrivers and a hammer, tap out the snap ring
Trang 1435 REMOVE GEAR SHIFT FORK SHAFT NO.3
(a) Using 2 screwdrivers and a hammer, tap out the snap ring from gear shift fork shaft No 3
(c) Using a magnetic finger, remove the 2 reverse shift fork balls from the reverse shift fork
(d) Using 2 screwdrivers and a hammer, tap the snap ring out of shift fork shaft No 3
36 REMOVE INPUT SHAFT ASSEMBLY
(a) Remove the input shaft assembly and output shaft assembly from the front transaxle case
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Trang 1537 REMOVE DIFFERENTIAL CASE ASSEMBLY
(a) Remove the differential case assembly from the front transaxle case
38 REMOVE MANUAL TRANSAXLE CASE RECEIVER
(a) Remove the bolt and manual transaxle case receiver from the front transaxle case
39 REMOVE REVERSE RESTRICT PIN ASSEMBLY
(a) Using a hexagon wrench, remove the reverse restrict pin plug from the manual transmission case
(b) Using a pin punch (φ5 mm) and a hammer, drive out the slotted spring pin and remove the reverse restrict pin assembly from the manual transmission case
40 REMOVE OIL RECEIVER PIPE NO 1
(a) Remove the bolt and oil receiver pipe No 1 from the manual transmission case
Trang 1641 REMOVE OIL RECEIVER PIPE NO 2
(a) Remove the bolt and oil receiver pipe No 2 from the manual transmission case
NOTICE:
Do not damage oil receiver pipe No 2.
42 REMOVE BEARING LOCK PLATE
(a) Remove the bolt and bearing lock plate from the front transaxle case
43 REMOVE TRANSMISSION MAGNET
(a) Remove the transmission magnet from the front transaxle case
44 REMOVE INPUT SHAFT FRONT BEARING
(a) Using SST, remove the input shaft front bearing from the front transaxle case
SST 09612-65014 (09612-01050, 09612-01060)
45 REMOVE FRONT TRANSAXLE CASE OIL SEAL
(a) Using a screwdriver, remove the front transaxle case oil seal from the transaxle case
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Trang 1746 REMOVE OUTPUT SHAFT FRONT BEARING
(a) Using SST, remove the output shaft front bearing from the front transaxle case
SST 09308-00010 NOTICE:
Do not apply excessive force to the front transaxle case when installing it.
47 REMOVE OUTPUT SHAFT COVER
(a) Remove the output shaft cover from the front transaxle case
48 REMOVE FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
(a) Using SST, remove the front differential case front tapered roller bearing (outer race) and plate washer from the front transaxle case
Do not damage the bearing.
49 REMOVE TRANSAXLE CASE OIL SEAL
(a) Using SST and a hammer, remove the transaxle case oil seal from the front transaxle case
Trang 18SST 09612-65014 (09612-01040, 09612-01050)
(b) Using SST, remove the front differential case rear tapered roller bearing (inner race) from the front differential case
SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00360)
NOTICE:
Do not damage the bearing.
51 REMOVE TRANSMISSION CASE OIL SEAL
(a) Using SST and a hammer, drive out the transmission case oil seal from the manual transmission case
SST 09950-60010 (09951-00530), 09950-70010 (09951-07150)
52 REMOVE SHIFT AND SELECT LEVER SHAFT OIL SEAL
(a) Using a screwdriver and hammer, remove the shift and select lever shaft oil seal
53 REMOVE SHIFT AND SELECT LEVER SHAFT SLIDE BALL BEARING
(a) Using SST and a hammer, remove the shift and select lever shaft slide ball bearing
Trang 19INSPECTION
1 INSPECT SYNCHRONIZER RING NO.3
(a) Check for wear and damage
(b) Coat the 5th gear cone with gear oil
(c) Turn the synchronizer ring in one direction while pushing it against the 5th gear cone
(d) Check that the ring locks
If the synchronizer ring does not lock, replace the synchronizer ring
(e) Using a feeler gauge, measure the clearance between the synchronizer ring back and the gear spline end
Minimum clearance:
0.75 mm (0.0295 in.)
If the clearance is less than the minimum, replace the synchronizer ring
2 INSPECT TRANSMISSION HUB SLEEVE NO.3
(a) Check the sliding condition between transmission hub sleeve No 3 and transmission clutch hub No 3.(b) Check that the edges of the transmission hub sleeve No 3 spline gear are not worn down
(c) Using vernier calipers, measure the width of the transmission hub sleeve No 3 groove (A) and the thickness of the claw part on the gear shift fork No 3 (B), and calculate the clearance
Trang 2029.931 mm (1.1783 in.)
If the inside diameter exceeds the maximum, replace the 5th gear
4 INSPECT REVERSE IDLER GEAR SUB-ASSEMBLY
(a) Using a caliper gauge, inspect the reverse idle gear
Standard inside diameter:
18.040 to 18.058 mm (0.7102 to 0.7109 in.) Maximum inside diameter:
17.966 mm (0.7073 in.)
If the outer diameter is less than the minimum, replace the reverse idler gear shaft
REASSEMBLY
1 INSTALL OUTPUT SHAFT COVER
(a) Coat the output shaft cover with MP grease and install it onto the front transaxle case
NOTICE:
Insert the output shaft cover projection into the case side hollow.
2 INSTALL OUTPUT SHAFT FRONT BEARING
(a) Coat a new output shaft front bearing with gear oil
Using SST and a press, install it onto the front transaxle case
SST 09950-60010 (09951-00550), 09950-70010 (09951-07150)
NOTICE:
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Trang 21• When replacing the output shaft front bearing, replace the output shaft front bearing inner race at the same time.
3 INSTALL FRONT TRANSAXLE CASE OIL SEAL
(a) Using SST and a hammer, install a new front transaxle case oil seal onto the front transalxe case
SST 09950-60010 (09951-00370), 09950-70010
(09951-07150) Drive in depth:
15.6 to 16.0 mm (0.6141 to 0.6299 in.)
(b) Coat the lip of the front transaxle case oil seal with
MP grease
4 INSTALL INPUT SHAFT FRONT BEARING
(a) Coat a new input shaft front bearing with gear oil, and using SST and a press, install it onto the front transaxle case
SST 09950-60010 (09951-00420), 09950-70010
(09951-07150) Drive in depth:
SST 09950-60010 (09951-00220), 09950-70010
(09951-07100) Drive in depth:
Trang 22SST 09350-32014 (09351-32120), 09950-60010 (09951-00530)
(b) Using SST and a press, install the front differential case front tapered roller bearing (outer race) together with the plate washer onto the front transaxle case
SST 09950-60020 (09951-00680), 09950-70010 (09951-07150)
8 INSTALL FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
(a) Using SST and a press, install the front differential case rear tapered roller bearing (inner race) onto the differential case
SST 09350-32014 (09351-32120), 09950-60010
(09951-00530)
(b) Using SST and a press, install the front differential case rear tapered roller bearing (outer race) with plate washer onto the transmission case
9 ADJUST DIFFERENTIAL SIDE BEARING PRELOAD
(a) Coat the differential case assembly with gear oil, and install it onto the front transaxle case
(b) Install the manual transmission case with the 16 bolts
Trang 23(c) Using SST and a torque wrench, turn the differential case assembly to the right and left 2 or 3 times to allow the bearings to settle
SST 09564-32011
(d) Using SST and a torque wrench, measure the preload
SST 09564-32011 Preload (at starting):
New bearing:
0.78 to 1.57 N*m (7.95 to 16.0 kgf*cm, 6.9 to 13.89 in.*lbf)
Used bearing:
0.49 to 0.98 N*m (5.0 to 10.0 kgf*cm, 4.34 to 8.67 in.*lbf)
If the preload is outside the specifications, select another plate washer
Plate washer thickness
(f) Remove the differential case assembly from the front transaxle case
Trang 2410 INSTALL TRANSMISSION CASE OIL SEAL
(a) Using SST and a hammer, install a new transmission case oil seal onto the manual transmission case
SST 09316-60011 (09316-00011) Drive in depth:
9.6 to 10.2 mm (0.378 to 0.402 in.)
(b) Coat the lip of the front transmission case oil seal with MP grease
11 INSTALL TRANSAXLE CASE OIL SEAL
(a) Using SST and a hammer, install a new transaxle case oil seal onto the front transaxle case
Drive in depth:
1.6 to2.2 mm (0.063 to 0.087 in.) SST 09710-20011 (09710-06071), 09950-70010
(09951-07150)
(b) Coat the lip of the transaxle case oil seal with MP grease
12 INSTALL TRANSMISSION MAGNET
(a) Clean the transmission magnet and install it onto the front transaxle case
13 INSTALL BEARING LOCK PLATE
(a) Install the bearing lock plate onto the front transaxle case with the bolt
Torque: 11 N*m (115 kgf*cm, 8.3 ft.*lbf)
14 INSTALL OIL RECEIVER PIPE NO 1
(a) Install oil receiver pipe No 1 onto the manual transmission case with the bolt
Torque: 17 N*m (175 kgf*cm, 13 ft.*lbf) NOTICE:
• Do not deform oil receiver pipe No 1.
• Install the oil receiver pipe No 1 while
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